ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2023 27 preparation process. It offers a range of advanced features that enhance efficiency and ease of use. Key features include: • High-speed and consistent cleaning and coating removal • Automated and optimized laser processing • Eliminates the need for abrasive materials or chemicals • Simplifies compliance with environmental and safety regulations Automated laser cleaning systems are well suited for diverse industries, including aerospace, energy, and automotive. It combines a powerful laser and an advanced beam delivery system with a 6-axis robot for precise part handling and motion control. Additionally, the Ablation LaserCell includes an integrated fume and debris collection system, ensuring cleanliness during operation. One of the system’s standout features is its offline programming capacity, along with a physics-based processing package. This enables efficient programming of robot paths, facilitating quick selection of process parameters and automatic fine-tuning. As a result, the setup process is streamlined, leading to enhanced productivity. 3D Printing and Cladding. 3D printing and cladding leverage the unique properties of laser beams to achieve precise control, high resolution, and versatility in material deposition. In 3D printing, lasers are utilized in a technique known as selective laser sintering or selective laser melting. These processes use a laser beam for layer-by-layer fusion of powdered materials, typically polymers or metals. The laser selectively heats and melts the powder, binding it together to form solid objects based on a digital model. Laser-based 3D printing offers numerous advantages. First, it allows the creation of intricate structures that would be challenging or impossible to produce using traditional techniques. This flexibility is particularly valuable in industries where complex components with lightweight designs or custom features are in demand. Additionally, laser-based 3D printing enables rapid prototyping and iterative design, saving time and costs. In 3D printing, spot sizes often need to be adjusted during the process. Changing beam spot size with external moving bulk optics is prone to optics contamination, expensive, results in energy losses, and slows down the printing. IPG developed a 3D printing laser source that allows on-the-fly change of the beam spot size from < 30 micron to ~2X larger in diameter without external optics. Control of the output powers for the two spots is independent, operating sequentially or superimposed in any fashion, speeding up the printing process. In cladding applications, manufacturers employ lasers to enhance or repair the surface properties of existing components. Cladding involves depositing a layer of material onto a substrate to improve its wear resistance, corrosion resistance, or other desirable characteristics. The laser beam melts the cladding material, typically in the form of a wire or powder, onto the surface of the substrate. The intense heat generated by the laser allows for precise control of the process, resulting in a well-bonded and uniform cladding layer. Microprocessing and Non-metals. Ultrafast lasers, those in the picosecond and femtosecond pulse durations, offer affordable fiber solutions with no thermal affectation. These lasers are ideal for critical applications such as cutting coronary stents. They are also well suited for cutting polymers and bioresorbable materials that may other- wise melt with longer pulse durations. Mid-infrared (IR) lasers operating at slightly longer wavelengths bring unique capabilities for clear-to-clear plastic welding. This is particularly appropriate for the clear polymer component widely used in the medical device industry, where darker polymers or additives are undesirable. Green and UV lasers offer higher photonic energy when compared to IR lasers. This enables coupling (absorption) of the laser light into a wider range of materials while minimizing thermal affectation, ideal for selective material removal applications such as parylene from sensitive electronic devices. Additionally, these lasers can be focused to a smaller spot size for higher precision applications, such as drilling high precision holes in drug- delivery devices. WORKING WITH APPLICATIONS LABS When delving into specific processes, it is crucial to collaborate with experienced and well-equipped applications labs. These labs are capable of conducting process experimentation and discussing the pros and cons of Fig. 4 — Well-equipped applications labs accelerate process development and optimization.
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